Simulation System For Aluminum Foil Cold Mill And Research Of Tension Control

This work was from the research project of Hebei Science and Technology Agency, "Research and Development of Intelligent Control System for Aluminum Foil Mill". The main contents include the following three aspects:first, semi-physical simulation platform for aluminum foil cold mill has been constructed; second, the mathematical model related to the tension control of the mill has been established; third, tension intelligent control system of fuzzy self-tuning has been schemed out. The concrete contents are as follows:First of all, based on the understanding of aluminum foil rolling theory and research in factory, the hardware platform of semi-physical simulation system, of which core is the process controller, has been set up. The hardware platform consists of PXI-1031 controller chassis, PXI-8186 embedded controller, PXI-6229 multifunction data acquisition card, SCB-68 signal conditioner and three computers for the host computers and the simulator.Next, the communication programs between the process controller and host computers, the man-machine interface of host computers and the virtual rolling mill programs in the simulation computer have been developed under the LabVIEW software development platform. The virtual rolling mill includes five parts:hydraulic system, tension system, speed systems, deformation system and two-dimensional animation display of the aluminum foil mill. The Virtual rolling mill receives instructions and parameters of aluminum foil stock from the process controller by the data acquisition card, then calculates displacement of hydraulic cylinder, rolling force, rolling thickness, speed and tension respectively and returns them to the process controller. The two-dimensional animation displays the whole rolling process and the rolling parameters vividly and directly.Once again, the tension function in the rolling process, the mechanism of tension generation and the tension control methods were elaborated detailed. The mathematical model related to the tension control of the uncoiler has been established, and the parameters of the model have been calculated according to the actual parameters of the mill. The simulation analysis which made in the semi-physical simulation platform proves that traditional PI control cannot achieve a satisfactory performance during the parameters of plant model has changed.Finally, the fuzzy self-tuning PI tension control system based on LabVIEW has been schemed out. Compared with the real-time simulation of traditional PI tension control which was done in the semi-physical hardware simulation platform, It is concluded that the fuzzy self-tuning PI tension control has the characteristics of quick adjustable speed, high stability and strong adaptability during the parameters of plant model has changed.The way of tension control research by constructing the semi-physical simulation platform for rolling mill has changed the situation that the simulation verification of former research results just by pure mathematics tools divorced from hardware foundation and established the foundation for practical application of intelligent control system for aluminum foil mill.